Method of manufacturing inverted organic solar microarray for applications in microelectromechanical systems

ABSTRACT

The fabrication and characterization of large scale inverted organic solar array fabricated using all-spray process is disclosed. Solar illumination has been demonstrated to improve transparent solar photovoltaic devices. The technology using SAM has potential to revolute current silicon-based photovoltaic technology by providing a complete solution processable manufacturing process. The semi-transparent property of the solar module allows for applications on windows and windshields. The inventive arrays are more efficient than silicon solar cells in artificial light environments, permitting use of the arrays in powering microelectromechanical systems and in integration with microelectromechanical systems.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. application Ser.No. 14/021,620, entitled “Inverted Organic Solar Microarray forApplications in Microelectromechanical Systems”, filed on Sep. 9, 2013,which is a continuation of prior filed International Application, SerialNumber PCT/US2012/028255 filed Mar. 8, 2012, which claims priority toU.S. Provisional Patent Application 61/450,425, entitled, “InvertedOrganic Solar Microarray for Applications in MicroelectromechanicalSystems and Others”, filed 8 March, 2011, the contents of which areherein incorporated by reference.

FIELD OF INVENTION

This invention relates to spray-manufactured organic solar photovoltaiccell. Specifically, the invention provides a novel method ofmanufacturing organic solar photovoltaic cells using spray-depositionand the organic solar photovoltaic cell resulting therefrom.

BACKGROUND OF THE INVENTION

In recent years, energy consumption has drastically increased, due inpart to increased industrial development throughout the world. Theincreased energy consumption has strained natural resources, such asfossil fuels, as well as global capacity to handle the byproducts ofconsuming these resources. Moreover, future demands for energy areexpected in greatly increase, as populations increase and developingnations demand more energy. These factors necessitate the development ofnew and clean energy sources that are economical, efficient, and haveminimal impact on the global environment.

Photovoltaic cells have been used since the 1970s as an alternative totraditional energy sources. Because photovoltaic cells use existingenergy from sunlight, the environmental impact from photovoltaic energygeneration is significantly less than traditional energy generation.Most of the commercialized photovoltaic cells are inorganic solar cellsusing single crystal silicon, polycrystal silicon or amorphous silicon.Traditionally, solar modules made from silicon are installed on rooftopsof buildings. However, these inorganic silicon-based photovoltaic cellsare produced in complicated processes and at high costs, limiting theuse of photovoltaic cells. These silicon wafer-based cells are brittle,opaque substances that limit their use. To solve such drawbacks,photovoltaics cell using organic materials have been activelyresearched.

The photovoltaic process in OPV first starts from the absorption oflight mainly by the polymer, followed by the formation of excitons. Theexciton then migrates to and dissociates at the interface of donor(polymer)/acceptor (fullerene). Separated electrons and holes travel toopposite electrodes via hopping, and are collected at the electrodes,resulting in an open circuit voltage (Voc). Upon connection ofelectrodes, a photocurrent (short circuit current, Isc) is created.

Organic photovoltaic cells based on π-conjugated polymers have beenintensively studied following the discovery of fast charge transferbetween polymer and carbon C60. Conventional organic photovoltaicdevices use transparent substrates, such as an indium oxide like indiumtin oxide (ITO) or like indium zinc oxide (IZO), as an anode andaluminum or other metal as a cathode. A photoactive material includingan electron donor material and an electron acceptor material issandwiched between the anode and the cathode. The donor material inconventional devices is poly-3-hexylthiophene (P3HT), which is aconjugated polymer. The conventional acceptor material is (6,6)-phenylC61 butyric acid methylester (PCBM), which is a fullerene derivative.Both the ITO and aluminum contacts use sputtering and thermal vapordeposition, both of which are expensive, high vacuum, technologies. Inthese photovoltaic cells, light is typically incident on a side of thesubstrate requiring a transparent substrate and a transparent electrode.However, this limits the materials that may be selected for thesubstrate and electrode. Further, a minimum thickness of 30 to 500 nm isneeded to increase conductivity. Moreover, the organic photoelectricconversion layer is sensitive to oxygen and moisture, which reduce thepower conversion efficiency and the life cycle of the organic solarcell. Development of organic photovoltaic cells, has achieved aconversion efficiency of 5.2% (Martin A. Green et. al., Prog. Photovolt:Res. Appl. 2010; 18:346-352).

Polymeric OPV cells hold promise for potential cost-effectivephotovoltaics since they are solution processable. Large area OPVs havebeen demonstrated using printing (Krebs and Norrman, Using light-inducedthermocleavage in a roll-to-roll process for polymer solar cells, ACSAppl. Mater. Interfaces 2 (2010) 877-887; Krebs, et al., A roll-to-rollprocess to flexible polymer solar cells: model studies, manufacture andoperational stability studies, J. Mater. Chem. 19 (2009) 5442-5451;Krebs, et al., Large area plastic solar cell modules, Mater. Sci. Eng. B138 (2007) 106-111; Steim, et al., Flexible polymer Photovoltaic moduleswith incorporated organic bypass diodes to address module shadingeffects, Sol. Energy Mater. Sol. Cells 93 (2009) 1963-1967; Blankenburg,et al., Reel to reel wet coating as an efficient up-scaling techniquefor the production of bulk heterojunction polymer solar cells, Sol.Energy Mater. Sol. Cells 93 (2009) 476-483), spin-coating and laserscribing (Niggemann, et al., Organic solar cell modules for specificapplications—from energy autonomous systems to large area photovoltaics,Thin Solid Films 516 (2008) 7181-7187; Tipnis, et al., Large-areaorganic photovoltaic module—fabrication and performance, Sol. EnergyMater. Sol. Cells 93 (2009) 442-446; Lungenschmied, et al., Flexible,long-lived, large-area, organic solar cells, Sol. Energy Mater. Sol.Cells 91 (2007) 379-384), and roller painting (Jung and Jo,Annealing-free high efficiency and large area polymer solar cellsfabricated by a roller painting process, Adv. Func. Mater. 20 (2010)2355-2363). ITO, a transparent conductor, is commonly used as ahole-collecting electrode (anode) in OPV, and a normal geometry OPVstarts from ITO anode, with the electron accepting electrode (cathode)usually a low work function metal such as aluminum or calcium, beingadded via thermal evaporation process.

In addition, to improve efficiency of the organic thin film solar cell,photoactive layers were developed using a low-molecular weight organicmaterial, with the layers stacked and functions separated by layer. (P.Peumans, V. Bulovic and S. R. Forrest, Appl. Phys. Lett. 76, 2650(2000)). Alternatively, the photoactive layers were stacked with a metallayer of about 0.5 to 5 nm interposed to double the open end voltage(Voc). (A. Yakimov and S. R. Forrest, Appl. Phys. Lett. 80, 1667(2002)). As described above, stacking of photoactive layer is one of themost effective techniques for improving efficiency of the organic thinfilm solar cell. However, stacking photoactive layers can cause layersto melt due to solvent formation from the different layers. Stackingalso limits the transparency of the photovoltaic. Interposing a metallayer between the photoactive layers can prevent solvent from onephotoactive layer from penetrating into another photoactive layer andpreventing damage to the other photoactive layer. However, the metallayer also reduces light transmittance, affecting power conversionefficiency of the photovoltaic cell.

However, in order for solar cells to be compatible with windows, issueswith the transparency of the photovoltaic must first be addressed. Themetal contacts used in traditional solar modules are visibility-blockingand has to be replaced. Another challenge is to reduce cost for largescale manufacturing in order for organic solar cells to be commerciallyviable, a much lower manufacturing cost to compensate for the lowerefficiency than current photovoltaic products. For example, asolution-based all-spray device, which was opaque, showed a PCE as highas 0.42% (Lim, et al., Spray-depositedpoly(3,4-ethylenedioxythiophene):poly(styrenesulfonate) top electrodefor organic solar cells, Appl. Phys. Lett. 93 (2008) 193301-193304).Large-scale manufacturing techniques, such as printing, have lowered thecost of manufacture, but still involve the use of metal in certain way,and therefore affect the transparency of the photovoltaic cell.

Therefore, what is needed is a new method of manufacturing organicphotovoltaic cells without the use of metal, to allow for novelphotovoltaic cells with enhanced transparency. Additionally, noveldevice architectures are needed for use in new technologies, such asmicroelectromechanical system (MEMS) devices. The art at the time thepresent invention was made did not describe how to attain these goals,of manufacturing less expensive and less complex devices, havingenhanced transparency or integration into MEMS devices.

SUMMARY OF THE INVENTION

The present invention is a novel way to fabricate organic solar arraysfor application in DC power supplies for electrostaticmicroelectromechanical systems devices and power sources for portablePDA devices.

An organic solar photovoltaic cell is disclosed which utilizes a SelfAssembly Molecule as an interfacial layer of the cell. The Photovoltaiccell comprises a substrate having a first face and a second face. Thesubstrate may be any material known in the art for use as a photovoltaicsubstrate. Exemplary materials include cloth, such as nylon cloth,cotton cloth, polyester cloth, hemp cloth, bamboo cloth, glass, such asa low alkaline earth boro-aluminosilicate glass, and plastic. Usefulglass is known in the art, and may include glass having a nominal sheetresistance of 4-10 Ohm/square. The substrate may be glass dimensionedinto 4″×4″ substrates. Exemplary plastics include any polymer such asacrylonitrile butadiene styrene (ABS), acrylic (PMMA), cyclic olefincopolymer (COC), ethylene-vinyl acetate (EVA), ethylene vinyl alcohol(EVOH), fluoroplastics, such as PTFE, FEP, PFA, CTFE, ECTFE, and ETFE,Kydex (an acrylic/PVC alloy), liquid crystal polymer (LCP),polyoxymethylene (POM or Acetal), polyacrylates (acrylic),polyacrylonitrile (PAN or acrylonitrile), polyamide (PA or nylon),polyamide-imide (PAI), polyaryletherketone (PAEK or ketone),polybutadiene (PBD), polybutylene (PB), polychlorotrifluoroethylene(PCTFE), polycyclohexylene dimethylene terephthalate (PCT),polycarbonate (PC), polyhydroxyalkanoates (PHAs), polyketone (PK),polyester, polyetherketoneketone (PEKK), polyetherimide (PEI),polyethersulfone (PES), chlorinated polyethylene (CPE), polyimide (PI),polymethylpentene (PMP), polyphenylene oxide (PPO), polyphenylenesulfide (PPS), polypropylene (PP), polystyrene (PS), polysulfone (PSU),polytrimethylene terephthalate (PTT), polyurethane (PU), polyvinylacetate (PVA), styrene-acrylonitrile (SAN).

An ITO layer is patterned onto the first face of the glass, forming ananode. The Self-Assembled Monolayer (SAM), such as N-propyltrimethoxysilane or aminopropyl triethoxysilane, are patterned onto theITO as a layer having a monolayer of molecules of about 2 nm or less,such as 2 nm. However, it is important that the thickness of SAM layernot be more than 2-3 layers of single molecules, i.e. having a thicknessof 10 nm or less. The SAM layer is covered by an active layer of P3HTand PCBM. The active layer of has a layer thickness of about 130 nm toabout 200 nm, such as about 130 nm or about 200 nm. A layer comprisingpoly (3,4) ethylenedioxythiophene:poly-styrenesulfonate and 5 vol. % ofdimethylsulfoxide is disposed on the active layer, providing the anodefor the photovoltaic cell with inverted structure. Optionally, thisanode layer has a thickness of about 100 nm to about 700 nm, and may be600 nm in some variations. Exemplary thicknesses include 200 nm, 250 nm,300 nm, 350 nm, 400 nm, 450 nm, 550 nm, 600 nm, 650 nm, and 700 nm.

The cell is sealed using a sealant such as a UV-cured epoxy encapsulantdisposed on the edges of the substrate.

The photovoltaic cells may also be in electrical connection, therebyforming an array. For example, a series of organic solar photovoltaiccells disposed into an array of 50 individual cells having active areaof 12 mm2. The array comprises 10 cells disposed in series in one row,and 5 rows in parallel connection in some variations.

A spray technique was also demonstrated to fabricate the photovoltaiccells and arrays, in conjunction with a novel Self-Assembled Monolayerof N-propyl trimethoxysilane. Compared to conventional technology basedon spin-coating and using metal as cathode contact, which greatly limitstransparency of solar cells and posts difficulty for large scalemanufacturing, the new spray technology solves these two problemssimultaneously. A thin film organic solar module is fabricated employingthis layer-by-layer spray technique onto desired substrates (can berigid as well as flexible). This technique has great potential inlarge-scale, low-cost manufacturing of commercial photovoltaic productsbased on solutions of organic semiconductors. This technology will getrid of high-vacuum, high temperature, low rate and high-costmanufacturing associated with current silicon and in-organic thin filmphotovoltaic products. Furthermore, this technology could be used on anytype of substrate including cloth and plastic. The method ofmanufacturing the organic solar photovoltaic cell comprises patterningITO on the substrate discussed above. The ITO patterns optionallyincludes obtaining an ITO substrate, and patterning the ITO usingphotolithography. In some variations, the ITO photolithography patternis sprayed onto the substrate using a custom made spray mask. Some ofthe ITO was then etched away from the substrate. In some varaitions, HCland HNO3 was used as an etchant, through any etchant known in the artappropriate for the ITO and substrate may be used. The etched substratewas then cleaned. Exemplary cleaning methods include sonification intrichloroethylene, acetone, and/or isopropanol. The substrate isoptionally cleaned at 50° C. for 20 min for each of three baths,trichloroethylene, acetone, and isopropanol, followed by drying with N2.

A Self Assembled Molecule layer, such as a layer of N-propyltrimethoxysilane or other self assembled molecule material known in theart like aminopropyl triethoxysilane (NH2) (Jong Soo Kim et. al., Appl.Phys. Lett. 91, 112111 (2007)), is applied onto the etched ITO glass.The Self-Assembled monolayer is annealed inside a glovebox. An activelater of P3HT and PCBM was formed by means and concentrations known inthe art. An exemplary solution is prepared my mixing P3HT and PCBM witha weight ratio of 1:1 in dichlorobenzene. This solution is optionallystirred on a hotplate for 48 h at 60° C. After preparation, the activelayer was sprayed onto the Self Assembled Molecule layer. Thepartially-assembled device dried in an antechamber under vacuum for atleast 12 hours.

A layer comprising poly (3,4)ethylenedioxythiophene:poly-styrenesulfonate mixed with 5 vol. % ofdimethylsulfoxide is formed by any means known in the art. For example,the poly (3,4) ethylenedioxythiophene:poly-styrenesulfonate was dilutedand filtered through a 0.45 μm filter followed by mixing thedimethylsulfoxide into the diluted poly (3,4)ethylenedioxythiophene:poly-styrenesulfonate. The poly (3,4)ethylenedioxythiophene:poly-styrenesulfonate solution was sprayed ontothe active layer and the device placed into high vacuum, such as 10-6Torr, for 1 h. The solar photovoltaic cell was then annealed andencapsulated with a UV-cured epoxy, which was cured with UV.

The inventive device and method has solved the costly and complicatedprocess currently used to make crystalline and thin film solar cells,namely, high-vacuum, high temperature, low rate and high-costmanufacturing. Furthermore, this technology could be used on other typeof substrate such as plastic. This new technology enables all solutionprocessable organic solar panel on with transparent contacts. Thistechnique has great potential in large-scale, low-cost manufacturing ofcommercial photovoltaic products based on solutions of organicsemiconductors. The use of self-assembled monolayer (SAM) modify thework function of ITO, and SAM was used in place of the previous Cs2CO3improving the device efficiency and reproducibility.

The present invention can be used to fabricate power source for smallelectronic devices. This technology also has potential to revolutecurrent silicon-based photovoltaic technology by providing a completesolution processable manufacturing process. The semi-transparentproperty of the solar module allows for applications on windows andwindshields. Additionally, these modules can be integrated into softfabric substances such as tents, military back-packs or combat uniforms,providing a highly portable renewable power supply for deployed militaryforces.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the invention, reference should be made tothe following detailed description, taken in connection with theaccompanying drawings, in which:

FIG. 1 is a diagram showing a perspective view of the novel inverted OPVcells containing sprayed-on layers.

FIG. 2 is a diagram showing the novel organic photovoltaic cell as itreceives photons having energy hv.

FIG. 3 is a graph showing current-voltage (I-V) of an inverted arrayusing SAM under continuous AM1.5 solar illumination measured atdifferent time points.

FIG. 4 is a diagram showing the cross sectional view of the devicearchitecture of an inverted solar array showing series connection.

FIG. 5 is a diagram of the device architecture showing a top view of thearray having a 4″×4″ organic solar array architecture. The array had anactive area of 3000 mm2 using 50 cells, at 10 cells in series per row,and 5 rows connected in parallel.

FIG. 6 is a diagram of the device architecture showing a top view of theinverted array using 1″×1″ organic solar cell array architecture. Thearray comprises 60-1 mm2 cells in series, forming a series microarray.

FIG. 7 is a diagram of the device architecture showing a top view of theinverted array using 1″×1″ organic solar cell array architecture. Thearray comprises 6 rows of 10-1 mm2 cells in series, connected inparallel, forming a parallel microarray.

FIG. 8 is a graph showing the current-voltage characterization oforganic solar microarray with Glass/ITO/SAM/Active/m-PEDOT architecturefor the parallel versus series arrays.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention for the fabrication of a see-through organic solararray via layer-by-layer (LBL) spray which is designed for integrationwith microelectromechanical systems (MEMS). The MEMS-OPV may beunderstood more readily by reference to the following detaileddescription of the preferred embodiments of the invention and theExamples included herein. However, before the present compounds,compositions, and methods are disclosed and described, it is to beunderstood that this invention is not limited to specific compounds,specific conditions, or specific methods, etc., unless stated as such.Thus, the invention may vary, and the numerous modifications andvariations therein will be apparent to those skilled in the art. It isalso to be understood that the terminology used herein is for thepurpose of describing specific embodiments only and is not intended tobe limiting.

As used herein, “about” means approximately or nearly and in the contextof a numerical value or range set forth means±15% of the numerical.

As used herein, “substantially” means largely if not wholly that whichis specified but so close that the difference is insignificant.

All masks described herein for spray were custom made by TowneTechnologies, Inc.

EXAMPLE

The indium tin oxide (ITO) is patterend onto a glass substrate using apositive photo resist, such as Shipley 1813, spin coated at 4500 rpm andsoft baked on a hotplate for 3 minutes at 90° C. The substrate is thenexposed to a UV-lamp for 1.4 seconds in a constant intensity mode set to25 watts. The structure was developed for about 2.5 minutes usingShipley MF319 and rinsed with water. The substrate was then hard-baked,at 145° C. for 4 minutes and any excess photoresist cleaned off withacetone and cotton. After cleaning, the substrate was etched from about5-11 minutes with a solution of 20% HCl-7% HNO3 on a hotplate at 100° C.The etched substrate was then cleaned by hand using acetone followed byisopropanol and UV-ozone cleaned for at least 15 minutes.

The Self-Assembled Monolayer (SAM) layer was formed on top of thepatterned ITO layer. A solution of N-propyl trimethoxysilane (3 mM) inethanol was prepared and stirred for 10 minutes at room temperature.Once the SAM solution was ready, the ITO substrate was placed in theprepared SAM solution and soaked for 36-48 hours inside an N2 gloveboxat room temperature. The SAM solution provides a single-layer thicknessof about, or less than, 2 nm. The substrate was then rinsed withethanol, followed by a toluene wash and an isopropanol wash, eachperformed for 10 minutes.

The active layer solution was prepared by mixing separate solutions ofP3HT (high molecular weight) and PCBM (C60) in dichlorobenzene at 20mg/mL and stirred on a hotplate for 24 hours at 60° C. These twoseparate solutions were then mixed together at a 1:1 ratio and stirredfor 24 hours at 60° C., producing a final solution of 10 mg/mL. Theactive coating was then spray coated onto the SAM layer using anairbrush with N2 set to 30 psi. The airbrush was set at about 7-10 cmaway from the substrate and multiple light layers of active layer weresprayed. For each spray, the solution used was about 600-900 μL.

A final thick continuous coat of active layer was applied onto themultiple thin layers to complete the active layer coating, forming athickness of between about 130 nm to about 200 nm. After drying, excessactive layer solution was wiped off of the substrate usingdichlorobenzene (DCB)-wetted cotton followed by isopropanol-wettedcotton. The substrate was then left to dry in the antichamber, undervacuum for at least 8-12 hours.

A kovar shadow mask was aligned in position with the substrate and heldin place by placing a magnet underneath the substrate. The seriesconnection locations were wiped using a wooden dowel to expose thecathode for later electrical connection.

The modified PEDOT (m-PED) layer was prepared by addingdimethylsulfoxide at a concentration of 5% by volume to a solution offiltered PEDOT:PSS. The solution was then stirred at room temperaturefollowed by 1 h of sonification. The m-PED coating was prepared byplacing a substrate/mask on a hotplate (90° C.). The m-PED layer wasspray coated using nitrogen (N2) as the carrier gas, set to 30 psi, withthe airbruch positioned about 7-10 cm from the substrate. Multiple lightlayers were applied until the final thickness of about 500 nm to about700 nm was reached. The substrate was then removed from the hotplate andthe mask removed. Care was taken to avoid removing the mPED with themask. The substrate was placed into high vacuum treatment (10-6 Torr)for 1 h, followed by a substrate annealing at 120-160° C. for 10 min.

The substrate was encapsulated using a silver paint applied to thedevice contacts, which were then allowed to dry. The encapsulation glasswas notched and cleaned by hand using acetone and isopropanol, followedby UV-ozone cleaning. UV-cure epoxy encapsulant (EPO-TEK OG142-12; EpoxyTechnology, Inc., Billerica, Mass.) was applied to the edge of theencapsulation glass, and the glass is placed into the glovebox for atleast 15 min, with UV exposure. The device was then flipped upside down,and the epoxy applied on top of the encapsulation glass. The device wasfinally exposed to 15 min of UV to cure the encapsulant epoxy.

Example 2

Inverted organic photovoltaic cell 1, seen dissected in FIG. 1, wascreated using the method described in Example 1. Inverted photovoltaiccell 1 was composed of different layers of active materials andterminals (anode and cathode) built onto substrate 5. Anode 10,comprised of ITO in the present example, was sprayed onto substrate 5forming a ‘

’ pattern extending from a first set of edges of substrate 5. SAM layer40 covers anode 10, except for the outermost edges, as seen in FIG. 2.The components of the SAM layer were chosen to provide a gradient forcharges crossing the interface, approximating a conventional p-njunction with organic semiconductors, thereby providing an increasedefficiency of heterojunctions. Active layer 30 is disposed directly ontop of interfacial buffer layer 40, and was prepared usingpoly(3-hexylthiophene) and 6,6-phenyl C61 butyric acid methyl ester.Anode 20 was disposed on the active layer in a pattern, similar to thecathode, but perpendicular to the cathode. Exemplary anode materialsinclude PEDOT:PSS doped with dimethylsulfoxide. The fully encapsulated 4μm×4 μm array was found to possess over 30% transparency.

The device was analyzed by exposing the cell to continuous radiation, asseen in FIG. 2. The photovoltaic cell was exposed to continuousillumination from a Newport 1.6 KW solar simulator under AM1.5irradiance of 100 mW/cm2. Current-voltage (I-V) results from continuousAM1.5 solar illumination from the UV lamp showed that the inverted arrayusing SAM under generated a voltage of Voc=1.2 V, current of Isc=3.2 mA,FF=0.23, and a power conversion efficiency (PCE) of 0.3% for the 3rdmeasurement, as seen in FIG. 3.

Example 3

Solar illumination has been demonstrated to improve solar arrayefficiency up to 250%. Device efficiency of 1.80% was observed with thearray under AM1.5 irradiance. Data have shown that the performanceenhancement under illumination only happens with sprayed devices, notdevices made by spin coating (See, Lewis, et al., PCT/US 11/54290). Thismeans that solar cells made using the present spray-on technique performbetter under sunlight, which is beneficial for solar energy application.

A solar array was prepared by forming 50 individual inverted cells asdescribed above, each with an active area of 3000 mm2. The array wasconfigured with 10 cells in series in one row to increase the voltage,and five rows in parallel connection to increase the current. Theneighboring cells were connected using the organic layer configuration,seen in cross section in FIG. 4 and top view in FIG. 5.

The photovoltaic cells were then prepared in a 1″ by 1″ array comprises60-1 mm2 cells in series, as seen in FIG. 6, and a 1: by 1″ array of 6rows of 10-1 mm2 cells in series, connected in parallel, as seen in FIG.7. The arrays were tested for current versus voltage, as seen in FIG. 8,to determine how the array configuration affects the performance of theinverted cell. As seen in the graph, the series array showed betterefficiency at 3V for the parallel array and around 10V for the seriesarray. The parallel and series arrays were integrated into MEMS devices,similarly to other power sources as is known in the art.

In the preceding specification, all documents, acts, or informationdisclosed does not constitute an admission that the document, act, orinformation of any combination thereof was publicly available, known tothe public, part of the general knowledge in the art, or was known to berelevant to solve any problem at the time of priority.

The disclosures of all publications cited above are expresslyincorporated herein by reference, each in its entirety, to the sameextent as if each were incorporated by reference individually.

While there has been described and illustrated specific embodiments ofan organic photovoltaic cell, it will be apparent to those skilled inthe art that variations and modifications are possible without deviatingfrom the broad spirit and principle of the present invention. It isintended that all matters contained in the foregoing description orshown in the accompanying drawings shall be interpreted as illustrativeand not in a limiting sense. It is also to be understood that thefollowing claims are intended to cover all of the generic and specificfeatures of the invention herein described, and all statements of thescope of the invention which, as a matter of language, might be said tofall therebetween.

What is claimed is:
 1. A method of manufacturing an organic solarphotovoltaic array; comprising the steps: forming a plurality of organicsolar photovoltaic cells, further comprising: patterning ITO onto asubstrate; applying a Self Assembled Monolayer layer onto the etched ITOglass, wherein the Self Assembled Monolayer layer comprises N-propyltrimethoxysilane or aminopropyl triethoxysilane; annealing the SelfAssembled Molecule layer inside a glovebox; spraying an active layer ofP3HT and PCBM on the Self Assembled Molecule layer; drying the solarphotovoltaic cell in an antechamber under vacuum for at least 12 hours;spraying a layer comprising poly (3,4)ethylenedioxythiophene:poly-styrenesulfonate mixed with 5 vol. % ofdimethylsulfoxide on the active layer; placing the solar photovoltaiccell into high vacuum for 1 h; annealing the solar photovoltaic cell;encapsulating the solar photovoltaic cell with a UV-cured epoxy; andintegrating the plurality of organic solar photovoltaic cells into anarray as depicted in FIG. 6 or FIG.
 7. 2. The method of claim 1, whereinthe patterning of the ITO further comprises: obtaining an ITO-coatedsubstrate; patterning the ITO using photolithography; etching the ITO;and cleaning the etched ITO and substrate.
 3. The method of claim 2,wherein the ITO photolithography pattern is sprayed onto the substrateusing a custom made spray mask.
 4. The method of claim 1, wherein theetching of the ITO is performed with a mixed solution of HCl and HNO3.5. The method of claim 2, wherein the etched ITO and substrate iscleaned by sonification in trichloroethylene, acetone, and isopropanol.6. The method of claim 5, wherein the cleaning is performed at 50° C.for 20 min each, followed by drying with N₂.
 7. The method of claim 1,wherein the active layer solution is prepared my mixing P3HT and PCBMwith a weight ratio of 1:1 in dichlorobenzene.
 8. The method of claim 7,wherein the active layer is stirred on a hotplate for 48 h at 60° C.prior to spraying.
 9. The method of claim 1, wherein the layercomprising poly (3,4) ethylenedioxythiophene:poly-styrenesulfonate mixedwith 5 vol. % of dimethylsulfoxide is prepared by: diluting the poly(3,4) ethylenedioxythiophene:poly-styrenesulfonate filtering the dilutedpoly (3,4) ethylenedioxythiophene:poly-styrenesulfonate through a 0.45μm filter; and mixing the dimethylsulfoxide into the diluted poly (3,4)ethylenedioxythiophene:poly-styrenesulfonate.
 10. The method of claim 1,wherein the high vacuum is 10⁻⁶ Torr.
 11. The method of claim 1, furthercomprising assembling the organic solar photovoltaic cell into an arrayof 50 individual cells with an active area of 12 mm².
 12. The method ofclaim 10, wherein the array is configured with 10 cells in series, inone row, and 5 rows in parallel.
 13. The method of claim 1, wherein theSelf Assembled Monolayer layer comprises N-propyl trimethoxysilane.